Metal plate reinforcement method

ABSTRACT

A metal plate reinforcement method includes: (a) providing a metal plate, in which the metal plate has a first surface and a second surface opposite to each other; (b) stamping the metal plate to form a plurality of first protruding portions protruding from the first surface; (c) respectively stamping the first protruding portions so as to respectively form a plurality of second protruding portions protruding at the second surface; and (d) flattening the second protruding portions to restore the metal plate.

RELATED APPLICATIONS

This application claims priority to Chinese Application Serial Number 201310470558.1, filed Oct. 10, 2013, which is herein incorporated by reference.

BACKGROUND

1. Technical Field

The present invention relates to a metal plate reinforcement method.

2. Description of Related Art

While a metal plate is subjected to metalworking, reinforcing ribs and supplemental ribs are formed at the metal plate to enhance structure strength. However, while a workpiece is formed at the metal plate or bonded to the metal plate by riveting process, the metal plate is vulnerable to downforce due to the workpiece or external force due to riveting process. Thus, the metal plate will sag and be deformed toward a specific direction. Sagging or deformation of the metal plate results in inconvenience while operators of production line want to assemble other parts at the metal plate. For example, if computer cases are deformed or sag, components such as printed circuit boards cannot be securely installed at the cases so that components such as printed circuit boards may be damaged by deformed computer cases.

To prevent the metal plate from being damaged, it is usually to enhance structure strength of the metal plate (e.g. pre-bending of metal plate or other design), make modification to die design and die molding. In addition, the metal plate is also prevented from damaged through strict quality control.

However, the foregoing solutions cause either cost increase or analytical cost and die-manufacturing cost. In addition, if a 1U server chassis is subjected to pre-bending process to enhance structure strength, then it may have difficulty in assembling computer or server. If other design is employed to maintain and reinforce chassis structure, then we need to solve space shortage of server or computer chassis.

SUMMARY

A metal plate reinforcement method includes the steps: (a) providing a metal plate, in which the metal plate has a first surface and a second surface opposite each other; (b) stamping the metal plate to form a plurality of first protruding portions protruding from the first surface; (c) respectively stamping the first protruding portions so as to respectively form a plurality of second protruding portions protruding from the second surface; and (d) flattening the second protruding portions to restore the metal plate.

According to one embodiment of the present invention, the foregoing metal plate has a first edge and a second edge opposite each other. A stamping zone formed by the first protruding portions extends between the first edge and the second edge.

According to one embodiment of the present invention, the first. protruding portions are r more concentrated near a center zone between the first edge and the second edge. The second protruding portions are more concentrated near the center zone.

According to one embodiment of the present invention, each of the first protruding portions has a same shape and size, and each of the second protruding portions has another same shape and size.

According to another embodiment of the present invention, a metal plate reinforcement method includes the steps: (a) providing a metal plate, in which the metal plate has a first surface and a second surface opposite each other; (b) stamping a plurality of first protruding portions on the metal plate to protrude from the first surface: (c) stamping a plurality of second protruding portions on the metal plate to protrude from the second surface; (d) flattening the first protruding portions and the second protruding portions to restore the metal plate.

In summary, the metal plate reinforcement method of the present invention use stamping process to stamp at both surfaces of the metal plate so as to form protruding portions. Then, the protruding portions are flattened to restore the metal plate. After flattening the protruding portions, shear stress flow of the metal plate interconnects so that a plurality of invisible “stress ribs” are formed. Thus, the metal plate reinforcement method of the present invention can solve the difficulties incurring in utilizing pre-bending sheet metal or employing other design to maintain and reinforce chassis structure. The metal plate is stamped and flattened so that the metal plate not only has enough structure strength and great flatness but also in compliance with space requirement.

It is to be understood that both the foregoing general description and the following detailed description are by examples, and are intended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be more fully understood by reading the following detailed description of the embodiment, with reference made to the accompanying drawings as follows:

FIG. 1 is flow diagram of a metal plate reinforcement method according to one embodiment of this invention;

FIG. 2A is a perspective view of a metal plate according to one embodiment of this invention;

FIG. 28 is a perspective view showing that first protruding portions are formed on the metal plate in FIG. 2A by stamping process;

FIG. 2C is a perspective view showing that second protruding portions are formed on the metal plate in FIG. 2B by stamping process;

FIG. 2D is a perspective view showing that the metal plate in FIG. 2C is restored;

FIG. 3A is a perspective view of another embodiment of the metal plate in FIG. 2B;

FIG. 3B is a perspective view of another embodiment of the metal plate in FIG. 2C;

FIG. 4 is flow diagram of a metal plate reinforcement method according to another embodiment of this invention;

FIG. 5A is a perspective view of a metal plate according to one embodiment of this invention;

FIG. 5B is a perspective view showing that the first protruding portions and the second protruding portions are formed on the metal plate in FIG. 5A by stamping process;

FIG. 5C is a perspective view showing that the metal plate in FIG. 5B is restored; and

FIG. 6 is a perspective view of another embodiment of the metal plate in FIG. 5B.

DETAILED DESCRIPTION

Reference will now be made in detail to the present embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts.

FIG. 1 is flow diagram of a metal plate reinforcement method according to one embodiment of this invention. FIG. 2A is a perspective view of a metal plate 1 according to one embodiment of this invention. FIG. 2B illustrates a perspective view showing that first protruding portions 100 are formed on the metal plate 1 in FIG. 2A. FIG. 2C illustrates a perspective view showing that second protruding portions 102 are formed on the metal plate 1 in FIG. 2A by stamping process. FIG. 2D illustrates a perspective view showing that the metal plate 1 in FIG. 2C is restored.

A metal plate reinforcement method of the present invention is shown in FIGS. 1-2D and includes steps S100˜S106.

At S100: Provide a metal plate 1 in which the metal plate 1 has a first surface 10 and a second surface (not shown and opposite to the first surface 10).

At S102: The metal plate 1 is subjected to stamping process so that a plurality of first protruding portions 100 protrude from the first surface 10.

At S104: The first protruding portions 100 are subjected to stamping process respectively so as to respectively form a plurality of second protruding portions 102 protruding from the second surface (sag from the first surface 10)

At S106: The second protruding portions 102 are flattened to restore the metal plate 1′. That is, the metal plate 1′ of FIG. 2C is flattened to form the metal plate 1″ of FIG. 2D.

According to one embodiment, as shown in FIG. 28, the metal plate 1 has the first edge 10 a and the second edge 10 b opposite each other. A first stamping zone Z1 formed by the first protruding portions 100 extends between the first edge 10 a and the second edge 10 b. The first protruding portions 100 are uniformly distributed within the first stamping zone Z1 (as shown in FIG. 2B), and the second protruding portions 102 are uniformly distributed within the second stamping zone Z1 (as shown in FIG. 2C).

Therefore, after the metal plate 1′ is subjected to stamping process and restored, the metal plate not only has great flatness but also uniform shear stress flow so as to enhance structure strength. According to one embodiment, the metal plate 1″ that is subjected to stamping process and restored can be subjected to another metalworking so as to form server chassis. However, the present invention is not limited to this.

Furthermore, as shown in FIGS. 2B and 2C, each of the first protruding portions 100 has a same shape and size, and each of the second protruding portions 102 has another same shape and size. However, the present invention is not limited to this. Parameters such as shapes, sizes, distribution, and density of the first protruding portions 100 and the second protruding portions 102 can be modified.

FIG. 3A is a perspective view of another embodiment of the metal plate 1 in FIG. 2B, and FIG. 3B is a perspective view of another embodiment of the metal plate 1′ in FIG. 2C.

As shown in FIG. 3A, according to one embodiment of the present invention, the first protruding portions 100′ are more concentrated near a center zone between the first edge 10 a and the second edge 10 b. That is, density of first protruding portions 100′ is gradually reduced toward the first edge 10 a and the second edge 10 b. As shown in FIG. 3B, according to one embodiment of the present invention, the second protruding portions 102′ are more concentrated near the center zone between the first edge 10 a and the second edge 10 b. That is, density of second protruding portions 102′ is also gradually reduced toward the first edge 10 a and the second edge 10 b. Thus, the metal plate 1″ that is subjected to stamping process and restored has more significant stress concentration at its central portion than at the first edge 10 a and the second edge 10 b. That is, structure strength of the metal plate 1″ is larger than that of the first edge 10 a and the second edge 10 b.

As mentioned above, compared the pattern of the first protruding portions 100 of FIG. 2B and that of second protruding portions 102 of FIG. 2C, the patterns of the first protruding portions 100′ (i.e. FIG. 3A) and second protruding portions 102′ (i.e. FIG. 3B) of the present invention have made the central portion of the metal plate 1″ much more robust to deformation. Thus, while the metal plate 1″ of the present invention is subjected to an object, sagging at central portion of the metal plate 1″ is not significant (e.g. less deformation).

Please refer to FIGS. 4, 5A, 58, and 5C. FIG. 4 is flow diagram of a metal plate reinforcement method according to another embodiment of this invention. FIG. 5A is a perspective view of the metal plate 3 according to one embodiment of this invention. FIG. 5B is a perspective view showing that the first protruding portions 300 and the second protruding portions 302 are formed on the metal plate 3 in FIG. 5A by stamping process, and FIG. 5C is a perspective view showing that the metal plate 3 in FIG. 5B is restored.

The metal plate reinforcement method of the present invention is shown in FIGS. 4˜5C and includes the steps S300˜S306.

At S300. Provide a metal plate 3 in which the metal plate 3 has a first surface 30 and a second surface (not shown and opposite to the first surface 30).

At 5302: The metal plate 3 is subjected to stamping process so that a plurality of first protruding portions 300 protrude from the first surface 30.

At S304: The metal plate 3 is subjected to stamping process so that a plurality of second protruding portions 302 protrude from the second surface (sag from the first surface 30).

At S306: The first protruding portions 300 and the second protruding portions 302 are flattened to restore the metal plate 3. That the metal plate 3 of the FIG. 5B is flattened so as to form the metal plate 3′ of the FIG. 5C.

According to the present invention, as shown in FIG. 5B, the metal plate 3 has the first edge 30 a and the second edge 30 b opposite each other. The first protruding portions 300 and the second protruding portions 302 form a stamping zone Z2 which extends between the first edge 30 a and the second edge 30 b of the metal plate 3. The first protruding portions 300 and the second protruding portions 302 are uniformly distributed within the stamping zone Z2.

Thus, after the metal plate 3′ is stamped and restored, the metal plate 3′ not only has great flatness but also uniform shear stress flow so as to enhance structure strength of the metal plate 3′.

FIG. 6 illustrates a perspective view of another embodiment of the metal plate 3 in FIG. 5B.

As shown in FIG. 6, according to one embodiment of the present invention, the first protruding portions 300′ are more concentrated near a center zone between the first edge 30 a and the second edge 30 b, and the second protruding portions 302′ are more concentrated near the center zone between the first edge 30 a and the second edge 30 b. That is, density of the first protruding portions 300′ is gradually reduced toward the first edge 30 a and the second edge 30 b of the metal plate 3, and density of second protruding portions 302′ is also gradually reduced toward the first edge 30 a and the second edge 30 b of the metal plate 3. Thus, the metal plate 3″ that is subjected to stamping process and restored has more significant stress concentration at the central portion than at the first edge 30 a and the second edge 30 b of the metal plate 3. That is, structure strength of the central portion of the metal plate 3″ is larger than that of the first edge 30 a and the second edge 30 b of the metal plate 3′.

As mentioned above, compared with the pattern of the first protruding portions 300 and the second protruding portions 302 of FIG. 5B, the pattern of the first protruding portions 300′ and the second protruding portions 302′ (FIG. 6) of the present invention due to the stamping process have made the central portion of the metal plate 3″ more robust to deformation. Thus, while the metal plate 3″ of the present invention is subjected to an object, sagging at central portion of the metal plate 3″ is not significant (e.g. less deformation).

From the aforementioned embodiments, it is apparent that the present invention provides a metal plate reinforcement method. The metal plate is subjected to the stamping process so that a plurality of protruding portions are formed at both surfaces of the metal plate. After the metal plate is subjected to the stamping process, the metal plate is flattened and restored so that shear stress flow of the metal plate interconnects so that a plurality of invisible “stress ribs” are formed. Thus, the metal plate reinforcement method of the present invention can solve the difficulties incurring in utilizing pre-bending sheet metal or employing other design to maintain and reinforce chassis structure. The metal plate is stamped and flattened so that the metal plate not only has enough structure strength and great flatness but also in compliance with space requirement.

Although the present invention has been described in considerable detail with reference to certain embodiments thereof, other embodiments are possible. Therefore, the spirit and scope of the appended claims should not be limited to the description of the embodiments contained herein. 

What is claimed is:
 1. A metal plate reinforcement method, comprising: (a) providing a metal plate, wherein the metal plate has a first surface and a second surface opposite each other; (b) stamping the metal plate to form a plurality of first protruding portions protruding from the first surface; (c) respectively stamping the first protruding portions, so as to respectively form a plurality of second protruding portions protruding from the second surface; and (d) flattening the metal plate.
 2. The metal plate reinforcement method of claim 1, wherein the metal plate has a first edge and a second edge opposite each other, and a stamping zone formed by the first protruding portions extends between the first edge and the second edge.
 3. The metal plate reinforcement method of claim 2, wherein the first protruding portions are more concentrated near a center zone between the first edge and the second edge, and the second protruding portions are more concentrated near the center zone.
 4. The metal plate reinforcement method of claim 1, wherein each of the first protruding portions has a same shape and size, and each of the second protruding portions has another same shape and size.
 5. A metal plate reinforcement method, comprising: (a) providing a metal plate, wherein the metal plate has a first surface and a second surface opposite each other; (b) stamping a plurality of first protruding portions on the metal plate to protrude from the first surface; (c) stamping a plurality of second protruding portions on the metal plate to protrude from the second surface; and (d) flattening the metal plate.
 6. The metal plate reinforcement method of claim 5, wherein the metal plate has a first edge and a second edge opposite each other, the first protruding portions and the second protruding portions form a stamping zone and are uniformly distributed at the stamping zone, and the stamping zone extends between the first edge and the second edge.
 7. The metal plate reinforcement method of claim 6, wherein the first protruding portions are more concentrated near a center zone between the first edge and the second edge, and the second protruding portions are more concentrated near the center zone.
 8. The metal plate reinforcement method of claim 5, wherein each of the first protruding portions has a same shape and size, and each of the second protruding portions has another same shape and size. 